Machine design, tập 84, số 12, 2012

They range from high-precision machine shops ENERGY EFFICIENCY During operation of the Cyclone engine, fuel is injected and burned in a centrifugal combustion chamber 1.. The Cyclone e

PIEZOELECTRICS ,

page 54

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MANUFACTURING & AUTOMATION

Edited by Leslie Gordon Leslie.Gordon@penton.com, Twitter @Leslie.Gordon

Machine shop produces complex, precision parts

From simple screw-machine parts to highly precise, intricately detailed parts, this shop’s up-to-date machines let it produce a wide variety of with up to 12 axes, letting it perform multiple operations at once The shop also has vertical-machining centers and

a secondary department that uses processes including thread rolling, knurling, polishing, slotting, deburring, drilling, and milling The firm can machine many different kinds of material, from 360 brass to 303 stainless and Nitronic 60 It can also machine different types of plastic.

How to increase positioning accuracy

Precision metric ball screws (PMBS) provide a cost-effective, high-precision actuator to aerospace, defense, medical, machine, and tool-making manufacturers To make the screws, the company uses advanced thread-rolling technology, letting it manufacture high- quality precision ball screws in a range

of sizes, diameters, and leads According

to company officials, precision metric ball screws provide a more cost-effective alternative for accuracy-intensive actuation and outperform standard thread-rolled ball screws Fully compliant with ISO 3408-3 and DIN

69051 standards, PMBS such as the MRT and PMT offer fine adjustment, accuracy, and repeatability for tight control positioning The availability of different mounting styles makes PMBS ball screws a good, interchangeable, domestically produced replacement for imported ground screws.

Is manufacturing

in the U S dead and gone?

The answer to this question — not really In fact, here are just a few examples of companies — either entirely based in the U. S

or with large manufacturing plants here — that have done well even during the recent downturn They range from high-precision machine shops

ENERGY EFFICIENCY

During operation of the Cyclone engine, fuel is injected and burned in

a centrifugal combustion chamber (1) Water in coils becomes superheated (2), then enters an adjustable valve (3), which distributes the steam into six radially configured cylinders The pistons’

motion turns the crankshaft (4) Steam escapes the pistons and is collected in a condenser, where it is turned back into a liquid (5) Blowers send fresh air around the condenser to speed cooling (6).

This Cyclone engine has been adapted for use on relatively small equipment, such as a lawnmower.

from practically any source, including biodiesel and gas, according to the company It is the basis for a new

syn-Dept and the U. S Army Tank Command, where it

could see service on the M1 Abrams tank, IAV Stryker, and Bradley Fighting Vehicle.

The engine uses the Rankine Cycle and ative external combustion, a com- bination the company calls a Schoell Cycle engine.

regener-Four basic processes take place inside the engine:

Heat process: omized fuel injected

At-mixes with air and is ignited Thermocouples control combustion duration

to keep heat in the chamber at

a constant temperature The heat then swirls around the heat coils Water in those coils becomes superheated steam (up to 1,200°F) and gets piped to

Even though combustion engines that use pistons and

new versions that improve efficiency and burn a wider

without building one first.

Here are several new approaches, or at least variations on earlier efforts, that offer a twist on conventional internal- though it is unlikely they will be em- braced by major automotive build- modification programs and efforts

— there are rumors of deals with

equipment such as generators and lawn mowers.

The Cyclone engine

The Cyclone engine from Cyclone

Power Technologies, pano Beach, Fla., is an external-combustion steam engine that can

Pom-be powered by heat

Engineers and inventors continue to tweak and refine piston-based combustion engines.

Authored by:

Stephen J Mraz

Staff Editor stephen.mraz@penton.com

Resources:

Cyclone Power Technologies, cyclonepower.com Doyle Rotary, doylerotary.com Grail Engine Technologies, www.grailengine.com Pinnacle Engines, www.pinnacle-engines.com

To see the Doyle Rotary engine in action, doylerotary.com/

For another feature on innovative

engines, scan this code or go to: http://

engines-0308

traditional gas or diesel engines of comparable power sions of the Cyclone engine ranging from 5 to 330 hp They can be used for portable or auxiliary power, automo- ment, or scavenging waste heat.

Grail engine

The Grail engine looks much like a traditional stroke engine, but incorporates some weight-saving re- finements that make it less expensive to manufacture And

two-the cylinders through an adjustable valve Valve timing controls torque and acceleration.

Mechanical process: Steam enters each of six ally configured cylinders under pressures as high as

radi-engine oil The pistons’ motion drives a spider bearing

can be connected directly to the drivetrain without a transmission In fact, a 38-in 3 Cyclone engine develops over 850 lb-ft of starting torque.

Cooling process: Steam exits the cylinders through exhaust ports and enters a condenser that turns it back to

to speed cooling Because this is a closed-loop subsystem, water need not be replaced.

Regenerative process: Air heated by the condenser travels to a heat exchanger where it preheats air coming

via heat exchangers around each cylinder, then to the ter of the coils to begin the heat cycle again.

cen-This design yields several advantages, including:

All-fuel capability: Fuel burns in an

external-combus-tion chamber under atmospheric condiexternal-combus-tions to create

algae, used motor oil, and fryer grease, as well as propane,

furnaces, as well as solar collectors.

Environmentally friendly: The engines

burn fuel longer than traditional ICEs,

lower, below the point at which harmful there is no oil to change, dispose of, or po- tentially leak And the exhaust is virtually sound waves into the air.

Efficiency: By keeping heat losses to a

minimum, the Cyclone’s fuel efficiencies has a power density of about 2.5 hp/in 3 , far more than traditional ICEs, which put out about 1.5 hp/in 3

Low cost: The Cyclone engine doesn’t

need a catalytic converter or muffler, nor

an oil pump or oil, and requires no mission With fewer parts, the engines is less expensive to manufacture and assem- ble And parts can be made of inexpensive,

On target

with off-beat engines

AUGUST 23, 2012 MACHINE DESIGN.com

www.machinedesign.com/rsc

VOLUME 84ISSUE 12AUGUST 23, 2012

64

Made in the U S A.

Here are just a few examples of companies

— either entirely based

in the U. S or with large manufacturing plants here — that have done well even during the recent downturn

On target with off-beat engines

Inventors are refining the traditional combustion engine in search of more power and efficiency from lost-cost alternatives

38

Small copper tubes make

a big impact on air-

conditioner efficiency

New developments in copper-tube

technology could pave the wave for

more-compact condensers and air conditioners

Plastics lose weight

with glass bubbles

Older grades of glass bubbles were

only suitable for zero to low-pressure

processes New glass bubbles are stronger

and small enough to meet OEM Class A

surface finish standards

Going places with

long-travel piezomotors

Piezomotors offer many advantages in

size, speed, vacuum compatibility, and

resolution, but haven’t been able to span

long distances That’s changing

Protecting fluid circuits with

edge-welded bellows

Compensating for expanding fluid

protects equipment and prevents leaks

2

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RS# 103

For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at reprints@pentonreprints.com or visit

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Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert Microfilm copies available from National Archive Publishing Company (NAPC), 300

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Subscription Policy: M ACHINE D ESIGN is circulated

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Printed in U.S.A., Copyright © 2012 Penton Media, Inc All rights reserved M ACHINE D ESIGN (ISSN 0024-9114)

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in January, February, June, July, and December by Penton Media, Inc., 9800 Metcalf Ave., Overland Park,

KS 66212

Paid subscriptions include issues 1-18 Issue No 19 (OEM Handbook and Supplier Directory) is available at additional cost Rates: U.S.: one year, $139; two years,

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$119; All other countries: one year, $99; two years,

SCANNING FOR IDEAS

Machine inserts different-sized pins in the same assembly

Pneumatic actuator handles linear and swiveling motion

Software simulates mechanical systems

with chains, gears, and belts

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Th ese have serious limitations

On hot summer days when the temperatures of the room and inside of the enclosure are about equal, there’s not enough diff erence for

eff ective heat exchange

to dependably cool and purge your electrical enclosures

Th ey convert an ordinary supply of compressed air intoclean, cold 20ºF air Th ey mount in minutes through an ordinary electrical knockout and have no moving parts to wear out Th e compressed air fi ltration that is provided keeps water, oil and other contaminants out of the enclosure

to react quickly to changes in air temperature. 0[JVZ[Z\W [V TVYL[VVWLYH[L[OHU ,?(09»Z,;**HIPUL[*VVSLYÆ :`Z[LT^P[O[OLZHTL:*-4 YH[PUNHUK)[\OYV\[W\[

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Opening the panel door

and aiming a fan at the

circuit boards is a bad idea

line up of coolers that are prone to bad behavior

What’s new online machinedesign.com

Editors Web picks

Overnight motors

PittmanExpress is an online system for ordering

prototype parts that ship in 24 hr Users can quickly

obtain brush-dc,

brushless-dc, and gearmotors

in various frame sizes and

ratings for concept testing

and evaluating products

for specific applications For

more information, visit www.

pittmanexpress.com.

Comprehensive bearing catalog

NKE Austria’s new General

Catalogue runs more than 1,000

pages It contains comprehensive

data on the company’s standard

bearings and information on

custom products The technical

section helps engineers select

bearing types and sizes and

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speed ratings Order the free CD

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Product-configurator tool

Wittenstein’s Product Configurator Design Tool fills

the gap between the company’s online Product CAD Generator and Cymex servosizing software The tool helps

engineers select and size gearboxes and includes a gearbox-to-motor system configurator and a database of

over 7,000 motors Learn more at www.

wittenstein-us.com.

Power-supply Apps

TDK-Lambda has released the Power

Supply Glossary App for iPhone and Android mobiles It contains a library

of power-supply terms and provides a useful selection of relevant calculators The company also offers a power- supply selector App They are available

at http://us.tdk-lambda.com/lp/about/

phone-apps.htm.

Hydraulic brakes

MICO Inc.’s new Web site (www.

mico.com) covers hydraulic brakes,

actuators, valves, and controls and offers info on vehicle dynamics The braking and stability-control systems are intended primarily for heavy-duty, off-road, commercial, and industrial applications.

Electric ZTR mower

Editor Leland Teschler talks to the owner of specialty vehicle manufacturer

Lawless Industries about an all-electric 60-in cut zero-turning-radius lawn

mower It has five permanent-magnet dc motors and can cut up to four acres

on a single charge Advantages over gas-powered machines include no exhaust

and much quieter operation See

it mow at www.engineeringtv.com/

Law;Only-Engineering-TV-Videos.

video/All-Electric-Lawn-Mowers-at-DESIGNENGINEERING

CONFERENCE AT IMTS

Engineers interested in the latest techniques for improving

machine efficiency, predicting failure and downtime

before it happens, and getting a look at controllers of the

future should attend The Motion, Drives and Automation

Conference, to be held September 10th and 11th in Lakeside

Hall of Chicago’s McCormick Place.

The conference is part of the IMTS Show and is

organized by M ACHINE D ESIGN and Hydraulics & Pneumatics

It will feature two in-depth conference tracks running

simultaneously, Motion Control in Automation and Hydraulics & Pneumatics in Automation

Other topics include security in industrial automation; mechanical and structural factors to consider when designing high-speed, high-precision motion systems; and

“Think like a machinist,” which will offer practical tips on how

to design easier-to-manufacture components The power track will include sessions on closed-loop position and force control; and designing more-reliable, efficient, and

fluid-quieter systems Learn more at www.imts.com/education/ motionConference.html.

AUGUST 23, 2012 MACHINE DESIGN.com

6

952 895 6400 | www.continentalhydraulics.com

RS# 105

But some of the measures undertaken to correct these trends might lead you to conclude that school administrators and educational advocates, rather than students, are the ones who could benefit most from better math skills Consider one of the measures that was supposed to improve the public second-ary education: hiring more teachers Since 1970, labor statistics show that the public school workforce has doubled, with two-thirds of the increase devoted

to teachers or teachers’ aides Meanwhile, secondary-school enrollment rose by just 8.5% It is fair to ask why no one in the educational infrastructure noted the difference in these two trends long ago and began posing some hard questions

An even-more interesting case of bad math arose in the late 1990s when the Bill and Melinda Gates Foundation gave grants totaling about $1.7 billion to a movement directed toward breaking up large schools into smaller ones The idea came from the claim that student achievement improves when schools are smaller The evidence for this assertion was that there is an unrepresen-tatively large proportion of smaller schools among high-performing educa-tional institutions

But there was a problem with the reasoning behind the smaller-is-better movement It was explained by University of Pennsylvania statistics expert Howard Wainer and McGill University’s Harris Zwerling Promoters of this idea, said the two statisticians, either didn’t know about or ignored the findings

of French mathematician Abraham de Moivre who, in 1730, showed that small samples have high variations Specifically, he demonstrated that the standard deviation isn’t proportional to the sample size, but instead rises in proportion

to the square root of the sample size

It isn’t surprising that small institutions show up more frequently in lists of better-than-average schools, the two said The performance of small schools is more variable than that of large schools, so overrepresentation at extremes is to

be expected To prove their point, Wainer and Zwerling looked at the 50 scoring schools in Pennsylvania, where they had academic data to work with

lowest-It turned out that smaller schools were overrepresented in this group as well.There were a lot of complaints about the smaller-school movement It emerged that “teachers ended up teaching things they don’t really know,” as

a Seattle newspaper article concluded Speaking of the small-school ment, one Michigan State University educator said, “I’m afraid we have done

move-a terrible disservice to kids.” Eventumove-ally, the Gmove-ates Foundmove-ation stopped giving grants to promote the idea

Wainer has more direct comments on this episode “Spending more than a billion dollars on a theory based on ignorance of de Moivre’s equation sug-gests just how dangerous that ignorance can be.”

The economics Nobel Prize winner Daniel Kahneman also read about the small-school debacle and said he found it “amusing.” One wonders if, after spending close to $2 billion on a misguided idea, Bill and Melinda Gates are as amused by it as Kahneman

— Leland Teschler, Editor

RS# 107

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EDITORIAL STAFF

1300 E 9th St Cleveland, OH 44114-1503

EDITOR

Leland E Teschler leland.teschler@penton.com

MANAGING EDITOR

Kenneth J Korane ken.korane@penton.com

SENIOR EDITORS

Leslie Gordon leslie.gordon@penton.com Stephen J Mraz stephen.mraz@penton.com

ASSOCIATE EDITORS

Lindsey Frick lindsey.frick@penton.com Robert J Repas, Jr.

robert.repas@penton.com

INDUSTRY COVERAGE: AUTOMOTIVE, PACKAGING,

EDITORIAL PRODUCTION

Denise Greco Editorial Production Manager Randall L Rubenking Art Director

RS# 109 RS# 108

AUGUST 23, 2012 MACHINE DESIGN.com

10

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LETTERS TO THE EDITOR

Please include your name, address, and daytime phone number Letters may

be edited for brevity and to focus on essential points.

Mail: Letters, MACHINE DESIGN,

1300 E 9th St., Cleveland, OH

44114-1503, Fax: 216-621-8469 E-mail, Editorial:

mdeditor@penton.com

function properly upon tion This statement is like saying that any clerical secretary, trained

comple-to put two complete sentences comple-gether can be a “Senior Editor” at

to-MACHINE DESIGN

Steven D Mueller

It’s a common complaint I have heard

at many engineering and software trade shows and events: There should

be a clearer distinction between signer” and “engineer.” Many com- plain what many so-called “design- ers” really do is just create a geometry

“de-Period There is no understanding of whether the device will actually work

in the real world In contrast, the term

“engineering” or “engineer” implies the necessary knowledge of the un- derlying physics or mechanics that makes stuff tick and really work — Leslie Gordon

Don’t blame the softwareYour recent editorial, (“PowerPoint Can Kill,” June 14) says: “To most en-gineers, the idea of using graphs or models to convey concepts comes

as second nature.” And you tion readers not to take PowerPoint lightly To this concern, I’d like to add that the Internet can also nega-tively affect our thought processes

cau-For example, when we read print,

we generally comprehend and member more than when we read the same text online It doesn’t help that online articles are often crammed with links that seem to interfere more than enlighten

re-The deep reading that comes naturally with print can be a strug-gle online That’s because printed documents induce an attentive-ness in which reading is more than skimming The computer, once our

Engineers are not CADs

I strongly disagree with the first

part of Leslie Gordon’s

commen-tary (“Does Model-Based

Engineer-ing Make Sense?” June 14) She

wrote: “Design is merely creating

the geometry Any CAD jockey can

do ‘design.’ Engineering, on the

other hand, uses physics-based

rules to develop functional

ma-chines and mechanisms.”

I believe she is confusing the

issue It is certainly not true that

any CAD jockey can do “design.” It

might be true that any CAD jockey

can do drafting, which might be

classified as drawing what has

al-ready been designed True design

can involve a huge amount of

cre-ativity, and it is concerned with

form, function, and costs, among

other things Good designers may

also need to understand

engineer-ing fundamentals, and work hand

in hand with more analytical

en-gineers to ensure the integrity of

their designs

Not all engineers make good

de-signers (although some do), because

they aren’t creative or don’t have the

common sense to get out of the

rain They might be good computer

jockeys, number crunchers, and

un-derstand Newtonian mechanics or

antenna theory, but wouldn’t know

how to “create” something if their life

depended on it

W D Robins

In the commentary by Leslie

Gor-don, she made the blanket

state-ment that “Any CAD jockey can do

‘design.’”

Now I may be new to the

de-sign and engineering field since

I have only been involved since

the 1970s, and I am not a degreed

engineer, but is she really

seri-ous? I have been trained in

draft-ing, mathematics, science, physics,

multiple CAD formats, and came

up through in the school of hard

knocks There are people trained

to use CAD (including engineers)

who can barely put two lines

to-gether, much less turn out designs

for equipment that can be

manu-factured, assembled, and actually

servant, now becomes our master And online content may be less im-portant than the medium itself So, while we enjoy the Internet’s ben-efits, we should question if we are sacrificing our ability to read and think effectively

Ray Herzog

I am old enough to remember when engineers effectively com-municated long before there was such a thing as PowerPoint If you were lucky, you had an overhead projector for your meetings More frequently, you used a chalk board

It may sound primitive, but writing out your ideas and logic this way forced you to focus only on essen-tial points and think through your presentation beforehand It seems the problem with PowerPoint is that it lets speakers get by without this sort of thoughtfulness

And although I agree with you that too many presentations are just plain bad, PowerPoint is just the tool I do finite-element analy-sis for a living, so the software is

a necessity I have not found any other media tool that lets me show people what is going on with their parts But the main problem is not the tool, but the desire to automa-tize and oversimplify every task

Computerizing the profession

A host of readers didn’t take kindly to an editorial that said “any” CAD operator can

do design They didn’t appreciate being compared to what they consider com-puterized draftsmen Others felt the criti-cism of computer-based presentations was somewhat off-base as well

AUGUST 23, 2012 MACHINE DESIGN.com

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RS# 111

It seems our motto these days is,

“The less thinking, the better.”

Carlos Gutierrez

As a frequent (and hopefully

effec-tive) user of bullet points, I want to

dispel the notion that all bulleted

lists are signs of intellectual

lazi-ness They are not A good bullet

list can actually be the result of

intellectual rigor But it’s true that

bad bullet lists result from the

in-tellectual laziness you mentioned

or some other intellectual

short-coming But please don’t blame

the bullets And let’s make sure not

to blame Powerpoint either

I do appreciate that the editorial

brings attention to the hazards of

poor slides But again, lets make

sure to understand that poor slides

come from poor communicators

Placing a pen in the hand of a poor

communicator would likely result

in a technical paper just as bad as

their PowerPoints If one cannot

CorrectionThe June 14 arti-cle, “Energy-Effi-cient Hydraulics Slash Operating Costs,” contained

a n i n c o r r e c t graphic related

to energy sumption on in-jection-molding machines The correct version,

con-s h o w n h e r e ,

i n d i c a t e s t h a t replacing con-stant-speed, electrohydraulic variable-displacement pumps with vari-able-speed pump drives cuts energy consumption well in excess of 30%

create an organized bullet list (which is much like the outline for

a paper), how can one expect to create an organized paper?

The example of NASA’s

exces-0 1,000 2,000

0 5,000 10,000

5.6 kW 1.3 kW

41.4% 2.2 kW 33.1% 8.4 kW

50-ton, 30-sec cycle time

160-ton, 15-sec cycle time

Energy savings

speed pump

speed pump

Variable- speed pump

speed pump

Constant-Comparing energy consumption

Injection-molding machines

sive use of Powerpoint in lieu of technical papers is truly astound-

i n g, a n d h o p e f u l l y s o m e o n e learned a good lesson

Ralph Terow

RS# 112 AUGUST 23, 2012

MACHINE DESIGN.com

14

Introducing BEARINX®-online Easy Linear from Schaeffler: the free, of-the-art software that lets you easily calculate the basic rating life of adriven linear axis supported by rolling bearings in just 2 easy steps:Step 1:

state-Register online at http://bearinx-online-easy-linear.schaeffler.com/index_e.htmStep 2:

Enter the requisite data inputs for calculation

That’s it! The program even generates a comprehensive report for you

in pdf format

The latest addition to Schaeffler’s industry-leading lineup of onlinebearing calculation programs, BEARINX®-online Easy Linear isdesigned to save you time and money:

● Unlike other programs, BEARINX®-online Easy Linear takes intoaccount the influence of the rail and carriage’s elasticity on totalsystem deflection, thereby ensuring that your system is designedright the first time!

● With almost limitless input capabilities, bearing life projections are asaccurate as you want them to be Consequently, BEARINX®-online EasyLinear can keep you from over-sizing and over-spending!

Bottom line: your complex machine-axis calculations just got a wholelot easier

Schaeffler Linear Technology:

Exceptional Performance without Exception

www.schaeffler.us

E-5157

BOOTH NUMBER

SCANNING FOR IDEAS

Edited by Stephen J Mraz

For another article related

to specialty fasteners, scan this code or go to:

http://machinedesign.

that-maximize-assembly- life-1019

com/article/fasteners-Machine inserts

different-sized pins

in the same assembly

Request free information vi

a our Reader Service Web site atwww.machinedesign.com/

rsc

For high-volume jobs, it’s easy to

justify the cost of an automated

pin inserter Automation

improves consistency of

installation and efficiency

while cutting costs

and scrap But for

low-volume tasks, or jobs

that require different-size

pins, it has not always

been easy to justify the

cost of buying several

dif-ferent machines To solve

that problem, engineers

at Spirol International

Corp., Danielson, Conn

(www.spirol.com),

devel-oped the Model CR

Combina-tion InstallaCombina-tion Machine

It can install three completely

dif-ferent size pins in the same or three

different assemblies The modular

machine features separate vibratory

feeders and orientation heads for the

three different pins And there are

three interchangeable fixture nests,

one for each pinning application

Each nest has a centrally located

dowel pin that aligns the fixture to

the pin-exit bushing Precise dowel

holes are machined into the base

plate and lined up with each

pin-orientation head A single bolt

secures the fixture while in use

Each fixture is number

coded, making it easy for

opera-tors to ensure the right one is

loaded When a pinning

opera-tion is completed, the operator

re-moves the fixture, installs the next,

and puts the selector switch in the

corresponding position to begin the

next pinning operation The machine

can also be retooled with different

feeder-orientation heads and

fixture combinations

RS# 401

Micrometer-style adjustments control insertion depth

Three feeders for three different pin sizes

Retracting head simplifies loading and unloading parts

Solid-state microprocessor controls

Antitie-down dual optotouch activation

Interchangeable fixture nests

Hardened steel bushings for long life

Three pin orientation heads; one for each pin size

AUGUST 23, 2012 MACHINE DESIGN.com

16

RS# 114

SCANNING FOR IDEAS

Pneumatic actuator

handles

linear and swiveling motion

Engineers at Festo Corp.,

Hauppauge, N. Y (www.festo.com/

us), combined the company’s

stan-dard DNC cylinder with its DSM-B

semirotary actuator to create a

pneumatic swivel/linear drive unit,

the DSL-B The ready-to-install unit is

available in sizes from 16 to 40 mm

with strokes up to 200 mm, and both

swivel and linear motion can be

con-trolled individually or simultaneously

The unit’s sturdy ball-bearing guide lets it absorb relatively high levels of torque The swivel angle can be set anywhere from 0 to 270° Mechanical gearing between the braking ele-ment and swivel module prevents movement of the brake under load

And a recirculating ball-bearing guide contributes to precision, backlash-free swiveling, and helps resist torque loads during linear motion RS# 402

Two types of cushioning available:

hydraulic shock absorber or flexible cushioning elements

Swivel position determined

using proximity sensors

mounted on braking

subsystem

Swivel angle detected using magnet in braking lever

Flexible mounting surface

Graduated scale makes it easy to preset required angle

AUGUST 23, 2012 MACHINE DESIGN.com

18

Bosch Rexroth Corporation

www.boschrexroth-us.com/linearsystems

For faster, easier, more economical development of handling systems, Rexroth’s

EasyHandling approach is exactly what today’s deadline-driven OEMs and systems

integrators seek EasyHandling combines systematic and seamless integration of all drive and control technologies with linear actuators, standardized mechanical and electrical

interfaces, all supported by new start-up and commissioning tools to dramatically simplify the automation process Reduce development time by up to 80% and enable a more

effi cient and cost-effective engineering process.

Ingenious solution, Build handling systems faster

Exactly

RS# 115

REPORTER’S NOTEBOOK

Holland’s newest power plant:

A centuries-old windmill

There are over 1,000 old mills spread

over the Holland countryside, Last year,

one of them was the first to be retrofit

with an add-on package for generating

electrical power

The idea makes sense since experts

figure it takes about 10 kW to turn a mill

stone And mills are typically overbuilt:

Most generate about 240 kW

The mill chosen for retrofit dates to

1851 It turns at 4 to 24 rpm, and this

gets sped up by a factor of 10, thanks

to a special wheel The mill still uses

wooden gears, and though many have

been replaced over the years, they are

still built to original specifications So

the first step was to replace one of those

gears with a stronger version that used

reinforced plastic rollers

This new gear attaches to a

right-angle gearbox that lets the new

com-ponents fit inside the mill, which is

crowded with wooden beams It sends

power to a 10-kW generator through an

Ogura, Somerset, N J., electromagnetic

clutch sized to handle the anticipated

torques and speeds The generator

starts sending out electricity when its

input shaft turns at anywhere from 5 to

240 rpm The mill creates an average of

955 Nm of torque for the generator, and

the generator can only handle up to 540 Nm at 240 rpm The clutch has a static torque of 700 Nm so it can easily handle the loads Cycle rates and heat dissipation are not

a concern for the clutch The clutch can also disconnect the generator if power is not needed, if the miller needs power for grinding corn, or if strong winds cause an overspeed (exceeding 240 rpm at the clutch), at which point the clutch automatically disengages

There are no batteries, so power gets used in an tached meeting room and restaurant If these establish-ments do not need power, it goes into the national grid But before the 50-Hz power gets used or sent to the grid,

at-it goes through a grid-feed inverter for matching and synchronization

The entire retrofit cost about $55,000 to $67,000, but the “free” power replaces electricity that costs $0.26/kW-hr

in Holland, and that’s without the 19% VAT. MD

This 160-year old windmill is one of the latest electric plants

in Holland, thanks to a retrofit that included new gearing, an Ogura MMC70G clutch, and a 10-kW generator.

AUGUST 23, 2012 MACHINE DESIGN.com

20

Design-engineering conference

kicks off IMTS

how to maintain machines remotely while

protecting intellectual property and preventing

unwanted intrusions

• A look at next-generation machine controls

• Mechanical and structural factors

engineers should consider when

designing speed,

high-precision motion systems

Other topics include “Think like

a machinist.” This session addresses

the fact that many designers and

engineers learn solid modeling in

universities or technical schools and then start

design-ing machines and components without considerdesign-ing

whether the 3D CAD component can actually be

made The result: The machinist is often confronted

with parts that are unnecessarily difficult or

impossi-ble to make This discussion will offer practical tips on

how engineers and CAD/CAM users can design

easier-to-manufacture components that cost less, and offer

faster turnaround and higher quality.The Hydraulics & Pneumatics in Au-tomation track will include sessions on closed-loop position and force control, improving reliability, reducing noise, and designing systems that use less energy

With current pressures on performance, efficiency, security, and the environment, engineers are more pressed than ever for the most up-to-date educational information on manufacturing equipment and indus-trial automation systems The Motion, Drives and Au-tomation Conference offers the perfect opportunity

to obtain critical content during IMTS Learn more at

The Motion, Drives and Automation Conference,

to be held September 10th and 11th, will focus on improving the performance, efficiency, and security

of machines and automation systems

Engineers interested in the latest techniques for

improving machine efficiency, predicting failure

and downtime accurately, and getting a look

at CNCs and motion controllers of the future

should consider attending The Motion, Drives

and Automation Conference, to be held

Septem-ber 10th and 11th in Lakeside Hall of Chicago’s

McCormick Place

The conference kicks off the International

Manufacturing Technology Show (IMTS), which

takes place September 10th to 15th in

Mc-Cormick Place The conference is organized by

M ACHINE D ESIGN and Hydraulics & Pneumatics,

along with Hannover Fairs USA, the Assn for

Manufacturing Technology, and the National

Fluid Power Assn.

Motion, Drives and Automation will feature

two in-depth conference tracks running

simul-taneously, Motion Control in Automation and

Hydraulics & Pneumatics in Automation

Attend-ees who register for this two-day conference will

have access to both tracks Researchers,

execu-tives, and engineering experts will speak on

topics ranging from reducing costs and boosting

machine precision to advances in technology

and security in industrial automation

Individual sessions in the Motion Control in

Automation track will include:

• Methods for increasing machine efficiency

• Advances in predictive technologies for

assessing machine health

• Security in industrial automation, including

Thousands of enclosures

Hundreds of sizes

Next-day shipping

REPORTER’S NOTEBOOK

When technicians position solar arrays on orbiting

satellites, they don’t want to worry about electrical

noise and intermittent signals from the positioning

equipment

That’s why engineers at Moog Space and Defense

Group, East Aurora, N Y., developed a noise-free

potentiometer to gauge the position of actuators on

satellites Called QuieSense, the device provides

es-sentially noise-free feedback on the position of solar

array drives and antenna-pointing mechanisms

Traditional potentiometers usually employ a

conduc-tive wiper element that slides over resisconduc-tive material,

thus providing variable resistance Over time, the wiper

contact generates particle debris that prevents the wiper

from making solid contact with the resistive material The

result is electrical noise and signal drop-out

Moog says it has solved this problem by engineering

its potentiometer with membrane technology, not

un-like the kind used with iPod controls The wiper touches

a Kapton flex material patterned with a copper trace on

its bottom surface The trace, in turn, touches the

resis-tive material where the wiper pushes down This

con-struction eliminates the sliding resistive contact that

causes problems in ordinary potentiometers Moog also

had to qualify the device’s materials to meet spaceflight

requirements For example, the new potentiometer

operates in a vacuum and is expected to handle more

than 100,000 revolutions without creating signal noise

Moog settled on this design after studying

nu-merous position encoding technologies, including

capacitive and optical sensors, inductive sensors such

as resolvers and Inductosyns, and Hall-effect devices Moog concluded all these alternatives would force the satellite to carry more onboard electronics, an ex-pensive proposition, says Moog Most satellite makers rely on heritage electronic systems that would require redesign and requalification

Some membrane potentiometers Moog tested also used nonmetallic parts prone to permanent set when left at a given position for several months In satellites,

it is not uncommon for actuators to sit for years out operating So any type of permanent set is a show-stopper Moog eventually used technology based on

with-Hoffman & Krippner’s Sensofoil Hybrid, which is

vac-uum compatible and operates over a wide

tempera-Here comes the sun,

and the satellite knows it

QuieSense top Kapton layer

Hold-down points

Wiper assembly

ture range So the wiper rides on an upper membrane

protected by a highly flexible metal bond This keeps

dents from forming during inactive periods

The commercial version of the potentiometer used

a polyoxymethylene wiper, a material with limited

high-temperature performance (Moog engineers

de-termined the potentiometer would have to operate at

temperatures as high as 105°C.) So a Vespel polyimide

wiper went into the spaceflight version

Engineers concluded that as long as resistance

remained below 300 Ω, the potentiometer would not

have drop-out noise Even after 800,000 cycle tests,

Moog found that contact resistance remained below

163 Ω

Standard Sensofoil potentiometers can hit an lute linearity of around 1% Moog’s QuieSense noise-free potentiometers are trimmed to produce lineari-ties of better than 0.25%

abso-QuieSense devices could find use providing tion feedback in a variety of spaceflight applications such as thrust-vector control systems, which direct a rocket’s position A commercial satellite manufacturer has already opted to use the new potentiometer and actuators on a communications satellite scheduled for launch in early 2014 Moog is also developing QuieSense potentiometers sized to let satellite makers replace traditional potentiometers used on various spaceflight actuators. MD

posi-A cross-sectional view of the QuieSense potentiometer reveals

how the wiper presses on the Kapton flex circuit that lets a

copper trace touch a resistive track deposited on a substrate

A steel leaf spring prevents wiper pressure from putting a set

in the membrane even if there are years of inactivity.

The Moog QuieSense potentiometer will provide position feedback on antenna gimbals and solar array drives so satellites can optimize their signal reception and maximize the amount of solar energy they collect from the sun.

RS# 116

Wiper

Solar-array drive

Potentiometer Antenna

Solar panel

Antenna gimbal

Top Kapton flex circuit

Potentiometer cross section

Steel leaf spring

Spacer

FR4 substrate

Resistive track Copper trace

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RS# 117

REPORTER’S NOTEBOOK

Investment casting

goes digital

A research team at the Georgia Institute of

Technology has developed a new way to perform

investment casting The basic process dates back

thousands of years: Molten metal is poured into

an expendable ceramic mold to form a part The

mold is made by creating a wax replica of the

part to be cast The replica gets surrounded or

“in-vested” with a ceramic which dries and hardens to

form the mold The wax is then melted out — or

lost — to form a mold cavity into which metal is

poured and solidified to produce the casting However, creating the mold

currently involves a sequence of six major operations needing expensive,

precision-machined dies and hundreds of tooling pieces

In contrast, the Georgia Tech approach involves a device that builds

ceramic molds from CAD data, completing the task quickly and producing

few bad parts The new technique, dubbed large area maskless

photo-polymerization (Lamp), builds molds layer by layer (each 100-microns

thick) by projecting bitmaps of UV light onto a mixture of photosensitive

resin and ceramic particles, then selectively curing the mixture to

a solid

After the mold forms, the cured resin is burned away and the remaining ceramic is sintered

in a furnace The result is a ramic structure into which mol-ten metal — such as nickel-based superalloys or titanium-based al-loys — can be poured, producing highly accurate castings

ce-“We have developed a of-concept system which is turn-ing out complex metal parts It fundamentally transforms the way high-value castings are made,” says Suman Das, director

proof-of the Direct Digital ing Laboratory in the Manufac-turing Research Center “We’re confident our approach can lower costs by at least 25% and reduce the

Manufactur-number of waste parts by more than 90%, while eliminating 100% of the

tooling.”

A prototype Lamp machine currently builds six typical turbine-engine

airfoil molds in 6 hr Das predicts that a larger machine — currently being

built at Georgia Tech and scheduled for installation at a PCC Airfoils facility

in Ohio in 2012 — will create 100 molds at a time in about 24 hr

Although the current work focuses on turbine-engine airfoils, Das

believes the Lamp technique will be effective for making many types of

intricate metal parts He envisions companies sending out designs to

“digital foundries” and receiving test castings a short time later, much as

integrated-circuit designers send CAD plans to chip foundries today. MD

Here are several molds created using Georgia

Tech’s Lamp version of investment casting

(white), and parts made using those molds.

Resources:

Direct Digital Manufacturing Laboratory in the Manufacturing Research Center,

Georgia Tech, ddm.

me.gatech.edu

RS# 118

AUGUST 23, 2012

into a power source

Researchers at Rice University have developed a lithium-ion battery

that can be painted on virtually any surface The spray-on power source consists of five spray-painted layers, each representing components in a traditional battery — two current collectors, a cathode, an anode, and a polymer separator in the middle

Construction of a cell starts by spraying purified single-wall carbon nanotubes with carbon black particles onto a substrate to form a positive current collector The cathode of the battery is sprayed as the second layer in a binder containing lithium-cobalt oxide, carbon, and ultrafine-graphite (UFG) powder A polymer separator makes up the third layer using Kynar flex resin, poly(methyl methacry-late) or PMMA, and silicon dioxide The fourth layer, the anode, is a mix of lithium-titanium oxide and UFG in a binder The final layer is the negative current collector, a commercially available conductive copper paint that’s diluted with ethanol Once painted, the cell is infused with electrolyte, heat-sealed, and then charged

The polymer separator solves one of the major design problems: taining the mechanical stability of the cell Unless the separator is stable, the nanotube and cathode layers would peel off the substrate when the cell was flexed

main-In one experiment, nine of the lithium-ion cells sprayed onto bathroom tiles were connected in parallel The cells were topped with a solar cell that converted power from a white light to charge the cells When fully charged, the battery provided a steady 2.4-V output for 6 hr that powered

a set of LEDs arranged to spell out “RICE.”

Combining paintable batteries with the recently reported paintable solar cells might create an energy-harvesting combination that would be hard to beat Mass production should scale easily as spray painting is al-ready an industrial process

Researchers reported that the hand-painted batteries were remarkably consistent in their capacities, within ±10% of the target The cells were subjected to 60 charge-discharge cycles where they displayed just a small drop in capacity And “batteries” were airbrushed onto ceramic bathroom tiles, flexible polymers, glass, stainless steel, and even a beer stein to see how well they would bond with different substrate. MD

Nine bathroom tiles formed the substrate for

a spray-on battery test at Rice University A solar cell charged the parallel- connected cells which ran

an LED display of the word

© Allied Electronics, Inc 2012 ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc An Electrocomponents Company.

BRANDS YOU TRUST

For all your electronic components and electromechanical solutions

RS# 120

REPORTER’S NOTEBOOK

The adRover promotional vehicle sports an LED sign for customer messages The motion of the LED sign is controlled by a CC Actuator from Nook Industries Inc

The CCActuator is basically a ball screw and electric motor together with adjustable limit switches It can operate in either compression

or tension-loading applications

adScope Media LLC in Tempe,

Ariz., uses a special actuator to

control the movement of a large

LED screen located on what it

calls its adRover, an all-electric

promotional vehicle that carries

customer advertising A device

on the vehicle lifts, turns,

and directs the screen,

which rises from the

vehicle deck The CC

Actuator from Nook

In-dustries Inc., Cleveland,

positions the sign and

can be programmed with

a computer

The early model of the

adRover used hydraulics

to control the display’s

motion, but the hydraulic

system was too heavy

and had many ongoing

maintenance issues, such

as leaking hydraulic fluid

Hydraulics also did not

perform well in

tempera-ture extremes

adScope also

re-searched mechanical

systems that relied on

chains, pulleys, and

Sign of the times

Electronic actuator replaces

hydraulics in mobile billboard

MACHINE DESIGN com

28

belts It rejected those

methods for similar

reasons

The CC ear Actuator resolved the hydraulic weight and motion-con-trol issues found with the other ap-

lin-proaches “As a 21st century media

platform, there are certain

require-ments we had to meet,” says owner

Donal Moore “The vehicle must be

the right size, agile, and

environmen-tally friendly In addition, we had to

cost effectively deliver messages not

only to large events but to small and

medium-sized crowds as well.”

The CC Actuator controls the

400-lb LED screen — raising,

lower-ing, and turning the screen from side

to side “Using a mechanical actuator

driven by an electric motor was more

costly than belt and chain-driven

devices, but it was the most elegant

solution,” says Moore “The actuator

is compact, well tested, and more in

keeping with the modern look of the

adRover Quite simply, it provided

the best technical way to control the

LED screen’s motion.” MD

3D printing comes to micro-sized objects

Researchers at the Vienna University of Technology have created a 3D

printer that quickly prints objects on the order of microns in size The vice relies on a technique called two-photon

de-lithography The 3D printer uses a liquid resin that is hardened by a focused laser beam guided through the resin by scanning mirrors

The result is a hardened line of solid polymer a few hundred nanometers wide

“Until now, this technique was quite slow,”

says Jurgen Stampfl from the Institute of Materials Science and nology at TU Vienna “The printing speed used to be measured in millime-

Tech-ters per second Our device can do 5 meTech-ters in 1 second.”

To be able to hit such speeds, the steering mechanism of the mirrors had to improve, says Stampfl The mirrors are continuously moving during the printing process, so their acceleration and deceleration must be pre-cise to generate high-resolution results at record-breaking speeds

Chemistry was also important “The resin contains molecules which are activated by laser light,” says Stampfl “They induce a chain reaction in other components of the resin, so-called monomers, and turn them into

a solid.” These initiator molecules only activate when they absorb two photons at once, which happens in the center of the laser beam where its intensity is highest In contrast to conventional 3D printing, the new tech-nique can create solid material anywhere in the liquid resin rather than only on top of the previously created layer Therefore, the working surface needn’t be specially prepared before the next layer is formed, which saves

a lot of time A team of chemists led by Robert Liska at TU Vienna oped the special resin

devel-Researchers are now developing biocompatible resins that can be used

to create scaffolds to which living cells can attach themselves, allowing the systematic creation of biological tissues. MD

Resources:

The Vienna University of Technology,www.tuwien ac.at/en/

RS# 122

REPORTER’S NOTEBOOK

LOOKING BACK

10 YEARS AGO — 2002

New transmission for diesels: A new five-speed

automatic truck transmission, called TorqShift, for the

2003 F-Series Super Duty pickups and Excursion SUVs carrying 6.0-liter Power Stroke diesel engines, helps

provide smoother shifts, according to Ford Motor Co.

A control system monitors the engine, transmission, hicle speed, and driver inputs to optimize shift performance

ve-A tow-haul feature adds more control

by tailoring upshifts while carrying heavy loads, and it senses when there’s

a need for more braking and cally schedules the appropriate down-shift The control body uses solenoids

automati-to manage the clutch, eliminating the variability of conventional hydraulic spring/valve systems An improved torque converter maximizes low-speed torque, 550 lb-ft during peak operation

30 YEARS AGO — 1982

An electric wheelchair, for children

ages four to 16, is microcomputer controlled Called Min I-OR by its de-

velopers Saab-Scania and Permobil

AB, the chair maneuvers using a single

lever requiring little pressure Stepless speed regulation, in combination with

a pivot suspension, results in quick and exact reactions Seat size can be changed

to fit the child and its top speed of

6 km/hr can be lowered An electronic safety system continuously checks that the wheelchair is functioning correctly and, if not, stops it Also, if the control lever is released, the chair automati-cally brakes to a stop

50 YEARS AGO — 1962

A negative and quarter placed in

the Instant Photo Vendor yield an enlargement in 15 sec Users place a negative under a glass

plate, lower and hold

an exposure meter over the negative, set a lever

to match the reading, and drop a quarter in the slot Photographic paper is exposed to the negative and run through a solution, activating a developing agent in the paper The image is fixed

by a bath in the stabilizer solution The

machine, made by Quik-Chek tronics and Photo Corp., will enlarge

Elec-film ranging from 35 mm to standard

120 size Enlargements can be up to four times the negative size, or a maxi-mum of 5 × 5 in MD

AUGUST 23, 2012 MACHINE DESIGN.com

30

` Increased precision and quality through

synchronization and real-time capabilities

` Reduced costs through scalability and design

freedom – PC-based or embedded

` Investment security through openness and full

compatibility

` Increased productivity throughout the entire life cycle

through intelligent service and diagnostic functions

` Space-savings through compact systems and

REPORTER’S NOTEBOOK

COMPANY NEWS

APPLICATION VIDEOS/DVDS

Agilent Technologies, Santa Clara, Calif., is

offer-ing aerospace and defense videos on interference

mitigation, switch repeatability, and a new tool for

instrument control The 1 to 3-min videos keep you

on top of the latest test technologies in radar/EW,

MilComs, satellite, and ELINT/SIGINT Go to www.

agilent.com/find/ADVideos.

Also available is a DVD showcasing a composite

of the 2012 DesignCon educational forums &

work-shops Go to www.agilent.com/find/HSD-Pinpoint.

ACQUISITIONS

PI USA, Auburn, Mass., has announces its next step in the acquisition of miCos GmbH, Eschbach, Germany

PI (Physik Instrumente) LP, the U S operation of

piezo and nanopositioning

sys-tems manufacturer Physik mente GmbH, will now handle

Instru-sales, distribution, and service

of miCos products for the U. S.,

Mexico, and Canada MICOS USA will become Micronix USA PI is

a manufacturer of precision tion-control equipment, piezo sys-tems, piezomotors, and actuators for semiconductor applications, photonics, bio-nanotechnology, and medical engineering

mo-Ametek Inc., Berwyn, Pa., has

completed its acquisition of the

parent company of toren GmbH, a provider of ad-

Dunkermo-vanced motion-control systems Ametek acquired the business from Triton, a European private equity firm for approximately

$320 million

COMPANY RANKINGS

Altra Holdings Inc., Braintree,

Mass., has been ranked No 3 on

Boston Globe’s “100 Best

Perform-ing Public Companies in sachusetts’” Altra Holdings is a designer, producer, and marketer

Mas-of electromechanical transmission products

in one of the poorest provinces

in Cambodia The computers are powered by solar panels that NewAge helped to purchase and have installed NewAge chose the school because nearly 30% of its staff is originally from Cambodia

or of Cambodian descent

RS# 124 AUGUST 23, 2012 MACHINE DESIGN.com

32

Actuatorline has all the precision you need – and won’t keep you waiting

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RS# 125

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Innova-Sponsored by General namics C4 Systems, Scottsdale,

Dy-Ariz., there are 11 Edge tion Centers worldwide and over

Innova-250 Edge members TE tivity designs and manufactures over 500,000 products that connect and protect the flow of power and data

Connec-INFLUENTIAL PEOPLE

Scott Crump, CEO and chairman

of Stratasys, Minneapolis, was

voted one of the Top 20 influential people in the rapid-

most-technologies industry by TCT

Magazine Crump is the inventor

of the fused-deposition ing (FDM) method of 3D printing, the most widely used additive-manufacturing process Stratasys manufactures additive-manufac-turing machines for prototyping and producing plastic parts

model-PLATINUM-EFFICIENCY CERTIFICATION

TDK-Lambda, San Diego, a group company of TDK Corp.,

announces its Model HFE2500-48 2,500-W server power supply has been certified to the 80 PLUS plat-inum level for redundant, server, and data-center applications TDK-Lambda provides power sup-plies for industrial equipment MD

AWARDS

Kollmorgen, Radford, Va., , received two

distin-guished awards for operational excellence from

Toyota Industries Corp The first honor was a Global

Sourcing Special Award for Value-Add and the second for No Delivery Delays for the fifth consecutive year Kollmorgen, a provider of motion-control systems, was one of 11 suppliers, and the only U. S.-based sup-

NI JOINS THE NAVY

National Instruments, Austin, announced that

Lockheed Martin will integrate its PXI modular

instrumentation and platform products in the U. S

Navy’s electronic Consolidated Automated Support

System (eCASS) automated test-equipment family

The eCASS test stations are used for ship and

on-shore electronic subassembly diagnostics and repair

RS# 126 AUGUST 23, 2012 MACHINE DESIGN.com

34

Every 3.5 seconds, a Banner sensing solution is installed somewhere.

Being engineers, we’re trying to improve on that.

Solving automation challenges, one application at a time, for over 45 years

For nearly half a century, when industry has an automation challenge, they turn to Banner for solutions

And among the thousands of global sensing innovations engineered by Banner, many started as a

tailored response to a single customer’s needs Challenges solved quickly Efficiently And affordably

Responses that have helped to create over 30,000 products and applications, with more on the way

Because at Banner, engineering is not just part of our name, it’s what we do Every second

bannerengineering.com

vision sensing wireless I/O lighting & indication

© 2012 Banner Engineering Corp more sensors, more solutions RS# 127

“Innovation distinguishes between

a leader and a follower.”

- Steve Jobs

As the leading manufacturer of OEM pumps and compressors, our innovation in design and technology has helped our customers create new innovative products and become leaders

in their marketplace

For more information on how Thomas innovation can help you lead your industry, go to gd-thomas.com/md8

RS# 128

Improving Lives through Innovation TM

2220 SERIES BLDC COMPRESSOR

In my last commentary (“Does Model-Based Engineering

Make Sense,” June 14), I said, “Any CAD jockey can do

design.” This comment provoked a lot of feedback But a common complaint I

have heard at many engineering and software trade shows and events is there

should be a clearer distinction between the terms “designer” and “engineer.”

Most often, it seems to be the designer’s job to make products look “sexy” or

evoke emotion They just create a geometry, period They don’t really need to worry about whether the swooshy car exterior, for instance,

is optimized aerodynamically for the real world

In contrast, the term “engineer” implies the necessary knowledge to take or make a design and apply the underlying physics or mechanics that makes stuff tick and work in reality

In response to the poke at “CAD jockeys,” one reader, a designer who says he is not a degreed engineer, writes, “I have been trained in drafting, mathematics, science, physics, multiple CAD formats, and was brought up in the school of hard knocks.” So here it seems any distinction between the terms is blurry at best

Yet another designer says he has been a CAD jockey for more than 40 years “I wholeheartedly agree the more intelligence built into the initial models and assemblies, the quicker engineering can make informed decisions about functional-ity, life-cycle behaviors, form, fit, and function, and costing, all of which will lead to a better final design,” he says “It’s like ‘skel-

etal’ modeling on steroids.” Again, in this case, it would seem that this particular

designer has a lot of engineering know-how

An interesting post by Kelly Bramble on the Engineers Edge Engineering

Forum (http://tinyurl.com/cyzohca) sums things up neatly “When I talk design

and engineering, I get mixed reviews on my perceptions and descriptions

Typi-cally, when I describe or refer to engineering and design within large

organiza-tions, I view these professionals mostly as separate, but interactive, functions or

professions To me, design is often what one sees or interacts with Engineering

is ultimately the science or details that enable the design to last, endure the

ap-plied stresses and strains, and transfer heat energy Manufacturing is the

gate-way to bring design and engineering to reality I am aware that in many small

companies engineers wear many hats These hats include design, engineering,

and manufacturing.”

And “randykimball” at the same URL says, “I consider the design part to be

when I’m being creative and making an effort not to allow constraints to have

too large of a controlling aspect of my thought process I consider the

engineer-ing part to be when I apply sciences to establish the creative results into

con-strained reality So I see designing as the application of talent, and engineering as

the application of science … both are vital.”

Perhaps, therefore, it could be said that, in general, design seems to be more

of an applied art whereas engineering is more of an applied science But there are

obviously exceptions to this statement

Do you think a clearer distinction needs to be made between the terms, and,

if so, why? Write us, and we might print your answer here MD

ENERGY EFFICIENCY

During operation of the Cyclone engine, fuel is injected and burned in

a centrifugal combustion chamber (1) Water in coils becomes superheated (2), then enters an adjustable valve (3), which distributes the steam into six radially configured cylinders The pistons’ motion turns the crankshaft (4) Steam escapes the pistons and is collected in a condenser, where it is turned back into a liquid (5) Blowers send fresh air around the

condenser to speed cooling (6).

from practically any source, including biodiesel and gas, according to the company It is the basis for a new

syn-10-kW auxiliary power unit being built for the Defense Dept and the U. S Army Tank Command, where it

could see service on the M1 Abrams tank, IAV Stryker, and Bradley Fighting Vehicle

The engine uses the Rankine Cycle and

regener-ative external combustion, a bination the company calls a Schoell Cycle engine

com-Four basic processes take place inside the engine:

Heat process: omized fuel injected into the centrifugal combustion chamber mixes with air and is ignited Thermocouples control combustion duration

At-to keep heat in the chamber at

a constant temperature The heat then swirls around the heat coils Water in those coils becomes superheated steam (up to 1,200°F) and gets piped to

Even though combustion engines that use pistons and

cylinders have been around for almost a century and a

half, inventors and engineers are still coming up with

new versions that improve efficiency and burn a wider

range of fuels Some of these new engines may not be

practical or economical, but it’s difficult to know that

without building one first

Here are several new approaches, or at

least variations on earlier efforts, that

offer a twist on conventional

interncombustion engines (ICEs) And

al-though it is unlikely they will be

em-braced by major automotive

build-ers — they have their own

engine-modification programs and efforts

— there are rumors of deals with

Asian companies making small

cars, scooters, and self-powered

equipment such as generators and

lawn mowers

The Cyclone engine

The Cyclone engine from Cyclone

Power Technologies,

Pom-pano Beach, Fla., is an

external-combustion

steam engine that can

be powered by heat

Engineers and inventors

continue to tweak and

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